Securing spikes in pre-existing loosened spike cavities in railroad ties

ABSTRACT

Technology is disclosed by which loosened railroad spikes may be re-secured in pre-existing spike cavities in reconditioned or repaired railroad ties, i.e. novel, facile, on-site, non-complex, miniaturized pre-packaged, clean, non-labor intensive, non-equipment intensive ways of bonding or polymerizing pre-existing previously used railroad spike cavities in the field for again receiving railroad spikes in a secure manner, so as to repair damaged spike cavity walls and prevent moisture infiltration. Frangibly encapsulated bonding agent or polymerizable resin placed in pre-existing spike cavities is preferred.

FIELD OF INVENTION

The present invention relates generally to repair and/or reuse of reconditioned or repaired railroad ties and more particularly to providing technology for field use by which loosened spikes may be re-secured in pre-existing spike cavities in ties in an efficient, forcible, facile and cost effective way.

BACKGROUND

In regard to railroad ties formed of wood or plastic and composite materials, spikes are driven through apertures in two spaced tie plates, placed on top of each tie, into the solid material comprising the tie. In each instance, this creates a spike cavity in the tie. The extent to which, each spike, once fully driven, is held in place depending on compression and frictional forces existing at the interface between the tie material defining the associated spike cavity and the spike. If the spike loosens, the associated tie plate and/or rail will also loosen, creating a potential for damage, shorter expected life, potential for water infiltration and a danger for trains traveling over the track.

As stated above, to fasten the tie plate to the tie and in some cases the railroad rail to the tie plate, spikes are forcibly displaced through apertures in the tie plates and into the adjacent solid tie material. The upper portion of the spike is characterized by a broadened eccentric head which come to rest on the tie plate or the lower flauge of a railroad rail after the spike is fully driven through the aperture in the tie plate and into the solid tie material. Upon being fully driven, the spike is held in place by above-mentioned compression and frictional forces.

The function of the driven spikes is to hold the tie plates and rails of a railroad track in place allowing trains to travel along the spaced rails, sometimes at high speeds. Over time spikes often loosen. Loads imposed on the tie plates and railroad ties vary as a train passes thereover. The maximum load is instantaneous, i.e. when two spaced wheels of the locomotive and the railroad cars are directly above a given railroad tie. This greater force tends to drive the tie downward into the ballasts upon which the tie is supported. When the instantaneous load lessens, the tie moves upward toward the earlier position.

This up and down movement creates forces which tend over time to loosen the railroad spikes in their respective spike cavities. When this happens, play in the associated tie plate and/or rail section results, which further loosens the associated spikes.

Also, over time, train forces sometimes tend to cause the tie plates to become indented into the top of the associated tie, which also results in a loosening of the associated spikes.

For safety reasons, the problem of loosen spikes in a railroad must be solved in a timely manner. Furthermore, once a spike has loosened within its spike cavity, water infiltration into the spike cavity predictably occurs, which causes rotting of the tie at the spike cavity, when the material thereof is wood.

Heretofore, the loosened spike problem has been addressed in two ways. One method comprises removal of the loosen spike and insert a wooden plug into the associated spike cavity. The removed spike is then re-driven into the spike cavity, with the tie plug acting as filler to, in effect, reduce the lateral size of the spike cavity. This approach has proven unsatisfactory for long term repairs because the plug does not prevent water infiltration with resulting tie rot. Also, the plug sometimes does not tightly retain the re-driven spike in place.

The other approach comprised complex technology by which polyurethane foam is used to reduce the size of used spike cavity. A loose spike is first removed from the tie. Liquid polyurethane in 55 gallon drums are provided along with a complex, heavy, and expensive foam machine requiring two men and much labor to operate. The liquid polyurethane is transferred to 5 gallon pots, heated, activated and pumped as foam into the spike cavity. Curing time thereafter is lengthy and the proper time for re-insertion of the spikes into polymer fitted spike cavities is hard to estimate. To use this method, a section of the railroad must be shut down for an extensive period of time because this technology is advantageous only when a large number of loosen spikes are involved. In other words, the equipment and manpower requirement do not accommodate use only on one or a few ties. This technology is messy and clean up of the treated area and the workers is difficult, if not impossible. A malfunction of the on-site complex equipment requires the equipment to be returned to a remote site for repairs.

Given the problems of the prior art, it would be a major advancement to provide a facile, non-complex miniatured clean, non-labor intensive, non-equipment intensive way of bonding or polymerizing empty pre-existing spike cavities for again securely receiving railroad spikes, so as to repair damaged spike cavity walls and prevent moisture infiltration.

BRIEF SUMMARY AND OBJECTIVES OF THE INVENTION

In brief summary, the present invention overcomes or substantially alleviates problems of the past related to technology by which loosened railroad spikes may be re-secured in pre-existing spike cavities in reconditioned or repaired railroad ties. The present invention is directed to novel, facile, on-site, non-complex, miniaturized pre-packaged clean, non-labor intensive, non-equipment intensive ways of bonding or polymerizing pre-existing previously used railroad spike cavities in the field for again receiving railroad spikes in a secure manner so as to repair damaged spike cavity walls and prevent moisture infiltration. Frangibly encapsulated bonding agent or polymerizable resin placed in pre-existing spike cavities is preferred.

With the foregoing in mind, it is a primary object of the present intention to overcome or substantially alleviate problems of the past related to loosened railroad spikes.

It is another predominate object to provide technology by which railroad spikes may be secured in pre-existing spike cavities in railroad ties, on a small or large scale.

Another paramount object of this invention is to provide facile, on-site, non-complex, miniaturized pre-packaged ways of bonding or polymerizing a resinous material in pre-existing railroad spike cavities in the field for thereafter receiving railroad spikes in a secure manner.

A further important object is the provision of methodology and products for securing railroad spikes in previously used spike cavities, which is clean, involves limited labor and obviates any need for complex equipment.

A further object of significance is the provision of frangibly encapsulated bonding agent or polymerizable resin placed in used spike cavities to secure railroad spikes therein.

Another valuable object is the provision of a way for a metered or controlled amount of bonding agent or polimer creating resin to be placed in a pre-existing spike cavity for securing a spike therein and sealing the spike cavity against liquid and debris infiltration.

These and other objects and features of the present invention will be apparent from the following detailed description taken with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1 and 2 are fragmentary elevation views illustrating the above-mentioned spike loosen problem, in respect to two different types of tie plates;

FIG. 3 is an exploded perspective view of a railroad tie, rail, tie plate, spike, spike cavities and capsule containing bonding agent or polymerizable material in one spike cavity, in accordance with principles of the present invention with parts broken away for clarity;

FIG. 4 is a fragmentary perspective of a railroad tie having a tie plate mounted at the top surface thereof;

FIG. 5 is an enlarged fragmentary elevational view taken along lines 5-5 of FIG. 4;

FIG. 6 is an enlarged fragmentary elevational view, similar to FIG. 5, illustrating a capsule of the present invention located within a pre-existing railroad spike cavity;

FIG. 7 is an enlarged fragmentary elevational view, similar to FIG. 5, illustrating two capsules located within one pre-existing railroad spike cavity;

FIG. 8 is a perspective of one capsule embodiment of the present invention;

FIG. 9 is an enlarged cross-section taken along lines 9-9 of FIG. 8;

FIG. 10 is an enlarged fragmentary cross-section of another capsule embodiment, illustrating a smaller capsule within a larger capsule;

FIG. 11 is an enlarged fragmentary cross-section of a third capsule embodiment illustrating two smaller interior capsules contained within an outside larger capsule; and

FIG. 12 is an enlarged fragmentary cross-section of a fourth capsule embodiment illustrating a two compartment capsule.

DETAIL DESCRIPTION OF THE ILLUSTRATED EMBODIMENT

Reference is now made to the drawings wherein like numerals are used to designate like parts throughout. As set forth in some detail above, rail deflection from the weight of railroad cars, which is maximum when two car wheels are directly above a given railroad tie, as well as vibration and other loads imposed, tend to loosen spikes. Loosened spikes tend to allow tie plates to undesirably move up and down and, with some tie plates, also allow vertical displacement or load chatter between a railroad rail and an associated tie plate. Loosening of railroad spikes creates danger of rail malfunction with the possibility of railroad car or locomotive derailment. It also sometimes allows moisture to infiltrate into the associated spike cavity, which, with wooden railroad ties, can cause rot within the spike cavity further weakening the grasp between spike and the spike cavity. This invention addresses the problem of re-introducing railroad spikes into a fully inserted position in pre-existing spike cavities. The present invention provides facile, non-complex miniaturized ways of placing bonding agent or polymerizable resin cartridges into empty previously existing spike cavities for again fully receiving and securely retaining railroad spikes therein. The technology of this invention is clean, not labor intensive and does not require complex equipment. It may be used on-site on either a large or small scale. It is extraordinarily effective to retain spikes against subsequent loosening in their respective spike cavities.

FIGS. 1 and 2 are elevational views depicting, in each, a railroad tie 20, with a tie plate superimposed upon the top surface of the tie. The tie plate 22 FIG. 1 differs in configuration from the tie plate 24 of FIG. 2. Both have long been conventionally used in conjunction with railroad ties. A railroad tie plate, generally designated 22 and 24 is contiguously superimposed upon each tie 20, as illustrated in FIGS. 1 and 2, which is conventional. The changes by which the tie plate 22 of FIG. 1 and the rail 26 are secured are not illustrated, but are conventional. However, in FIG. 2, the rail 26 is illustrated as being designed to be held in place by railroad spikes, generally designated 28. The up and down displacement of the tie, tie plate and rail imposed by train loads, is illustrated by arrows 30 in both FIG. 1 and FIG. 2. Over time, it is commonplace for the displacement 30 to loosen some of the railroad spikes comprising a railroad track so as to create a vertical gap 32 between the head of one or more spikes 28 and its fully driven position. When this occurs, it must be detected by inspection at an early point in time and corrective action taken so that the loosened spikes are once more fully inserted into their associated spike cavities and reliably secured in that position for safety and low-maintenance purposes, among others.

FIG. 3 is an exploded view of the components of a railroad track assembly. The railroad tie 20 comprises a top surface 23 and a bottom surface 25. The railroad tie 20 is conventionally and usually made of wood, although other materials, such as high molecular weight synthetic resinous materials or dense composite materials, may be used.

The tie plate 22 of FIG. 1 is conventional. The tie plate 22 comprises a central flat region 29 upon which the bottom surface of a railroad rail, generally designated 26, is placed. The rail 26 shown in FIG. 1 is conventionally secured by clamping structure, not shown. A railroad spike 28 is driven through each tie plate aperture 40 in the tie plate 22 directly into the material comprising the tie 20 so as to create a spike cavity therein. This causes the spike to be compressively and frictionally grasped by the tie material to hold the tie in place. The tie plate 22 is illustrated as being conventionally secured to the tie 20 by four spikes 28, one of which is shown in FIG. 3.

The conventional spike 28, shown in FIG. 3, comprises a shank 34, rectangular in cross section, a distal beveled tip 36 and a proximal head 38. The head 38 of the spike is eccentric in relation to the spike shank 34, is substantially larger than the shank 34 and substantially larger than the apertures 40 in the tie plate 26. The apertures 40 are each sized to respectively slidably receive the shank 34 of a spike 28.

When assembled, the bottom surface of the tie plate 22 rest contiguously upon the top surface of the tie and the bottom surface of the rail 26 rests upon the central top surface 29 of the tie plate 22.

On occasions, previously fully inserted and later loosened spikes allow up and down clapping of the tie plate 22 against the top surface of the tie 20, causing an indentation 41. One way of eliminating the indentation 41 is to remove the rail 26 and tie plate 22 and sever, along dotted lines 43, the top portions of the tie which are defined in part by shoulders 41. Reassembly then takes place.

Reference is now made to FIGS. 4 and 5, which illustrate in fragmentary perspective and in elevation, railroad tie 20 having tie plate 22 mounted at the top surface 23 thereof using four spikes. From FIG. 5, it can be seen that the top surface 23 is substantially planar without an indentation.

Referring to FIG. 5, once the spike 28 is loosened in an upward direction from its original fully inserted position within the material comprising the tie 20 at spike cavity 42, water and debris can sometimes infiltrate the spike cavity 42. As water is allowed to infiltrate the spike cavity 42 the wooden material of the tie begins to decay. Once the tie material experiences decay, the tie material no longer significantly binds or grasps the associated spike 32.

Loosen spikes also create a potential danger of derailment. Furthermore, the life expectancy of the ties, tie plates, etc. is shortened by the damage done by the clapping phenomenon allowed by loose spikes.

The transportability and facile nature of the current invention is illustrated in FIG. 8 which depicts a hermetically seal capsule or vessel, generally designated 44. The capsule comprises a compact, self-contained frangible shell or wall 46 containing a bonding agent, such as epoxy, or a polymerizable resinous material such as foamable polyurethane. In some embodiments of the current invention, the interior of the capsule also houses an activator. Alternatively, an activator may be contained within a separate frangible casing or applied from a separate source. The capsule or capsules are of such a size as to be readily received within a vacant exposed pre-existing spike cavity and, when caused to open, dispense an exact metered amount of bonding agent or polymerizable resinous material.

FIG. 9 is an enlarged cross-section of the capsule 44 taken along line 5-5 of FIG. 8. The shell or wall 46 is comprised of a watertight frangible wall which entirely encapsulates an interior cavity 48 in hermetically sealed relation. The shell 46 of the capsule 44 may comprise frangible glass or a suitable frangible synthetic resinous material, which does not react with or degrade because of the resinous material contained within the capsule. The capsule 44 and its contents act as a plug of sorts in the spike cavity, both the shell and the bonding agent, such as epoxy, or non-activated polymerizable composition, such as polyurethane foam. Capsule 44 is preferably manually dropped into each spike cavity 42 being reclaimed.

Activator is added in the spike cavity. It may be in the capsule with polymerizable resin or in a second seperate capsule or applied from a separate source. Where the activator is water, a hand-held water dispenser may be used.

In FIG. 10, the activator is shown as being located within a smaller interior secondary sealed compartment or capsule 50, located within the larger encapsulated and sealed cavity 48. The smaller compartment 50 is comprised of a frangible wall 52 which entirely encapsulates and seals the smaller compartment 50. This creates an impermeable barrier between the material contained in encapsulated cavity 48 and material contained in the smaller compartment 50. The outer encapsulated cavity 48 typically contains a suitable resinous material and the compartment 50 contains a suitable activator. Alternatively, polymerizable synthetic resinous material may be located within the smaller compartment 50 and the activator in the outer encapsulated cavity 48. In this embodiment, activation occurs when both the outer shell 46 and the inner barrier 52 are ruptured, fractured or otherwise opened and the resinous material and activator commingle.

In FIG. 11, two interior frangible vessels 56 are illustrated. Each vessel 56 is located within encapsulated cavity 48 of FIG. 7. Each vessel 56 is comprised of a frangible exterior wall or barrier 57 which encapsulates and seals the vessel 56. Located within one vessel 56 is a resinous material 57. The other vessel 56 contains an activator. Activation occurs upon severing, cutting, or rupturing or otherwise opening the frangible barriers 57 of both vessels 56, causing commingling of the activator and the resinous material.

FIG. 12 is illustrative of another embodiment of the current invention in which the activator and the resinous material are kept separate by a frangible divider or membrane 58 located within the cavity 48 of the capsule 44. The divider 58 creates two sealed compartments within the capsule cavity 48 and thereby prevents premature commingling of the activator and the resinous material. The divider 58 is comprised of a suitable frangible material. Activation occurs upon breaking the divider 58, allowing the components to commingle causing polymerization of the resinous material.

Reference is now made to FIG. 6, which illustrates a single frangible vessel 44 inserted into a pre-existing spike cavity 42. After insertion of the vessel 44, the spike 32 is driven or otherwise forcibly displaced through the plate aperture 40 into the pre-existing spike cavity 42 and through the wall of the vessel 44 to release the resinous contents thereof. Activator is delivered to the released resinous from within the vessel 44 or from a separate source. Alternatively, the vessel 44 may be carefully fractured above the spike cavity 42, so as not to spill the resinous material elsewhere.

FIG. 7 illustrates two individual frangible capsules 44, one containing activator and the other containing a resinous material successively disposed within a pre-existing spike cavity 42. When spike 32 is displaced through an aperture 40 and fully into the spike cavity 42, the capsules are fractured and the contents thereof commingle causing activation and polymerization of the resinous material. Alternatively, the two frangible capsules 44 may be broken with care above the spike cavity 42 to avoid spilling elsewhere.

Upon activation, the resinous material coats the worn, decayed or damaged wood and provides protection against further decay. It fills the entire spike cavity so as to prevent water and debris infiltration into the spike cavity. It causes powerful adherence between the fully inserted spike and wall which defines the spike cavity.

Where a foamable polyurethane is used, activation causes the foam expands up to three times its original volume within the spike hole cavity. During expansion essentially all voids within the spike cavity and in the adjacent tie material are fitted. This insures the spike cavity is sealed against entry of moisture and debris. It also assures full coverage and coating of both the shank of the spike and wall material defining the spike cavity for prevention of spike loosening. The wall of the tie defining the spike cavity is repaired as well.

The invention may be embodied in other specific forms without departing from the spirit of the essential characteristics thereof. The present embodiments, therefore, are to be considered in all respects as illustrative and are not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. 

1. A method for affixing a railroad spike into a previously used railroad spike cavity: comprising the acts of: inserting adhering material contained within a frangible vessel into a previously used railroad spike cavity defined by a railroad tie surface; discharging the adhering material from the frangible vessel into the spike cavity; placing a spike into the spike cavity so that the adhering material firmly adheres to the spike and the surface defining the tie cavity.
 2. A method according to claim 1 wherein the inserting act comprises manually dropping the vessel into the spike cavity.
 3. A method according to claim 1 wherein the discharging act comprises rupturing a wall of the vessel in the spike cavity.
 4. A method according to claim 3wherein the rupturing act comprises tearing the vessel wall by inserting the spike into the spike cavity against the vessel.
 5. A method according to claim 3 wherein the discharging act comprises cutting the vessel wall with a hand-held cutting instrument.
 6. A method according to claim 3 wherein the discharging act comprises rupturing the wall of the frangible vessel prior to full insertion into the previously used spike cavity.
 7. A method according to claim 1 wherein the inserting act comprises placing a vessel containing epoxy in the spike cavity.
 8. A method according to claim 1 wherein the inserting act comprises placing a vessel containing foamable polyurethane in the spike cavity.
 9. A method according to claim 1 wherein the vessel is selected from the group consisting of frangible plastic and glass.
 10. A method according to claim 1 wherein the frangible vessel is comprised of spaced outer and inner walls creating two interior sealed chambers.
 11. A method according to claim 10 wherein the interior sealed chamber contains separate non-activated resinous material and an activator.
 12. A method according to claim 1 wherein the adhering material is selected from the group consisting of a bonding agent and a polymerizable resinous material.
 13. A method of re-securing a railroad spike in a pre-existing railroad spike cavity comprising the acts of: removing a loosened spike from a spike cavity to expose the spike cavity; inserting a containerized bonding agent or polymerizable resinous material into the exposed spike cavity; discharging the bonding agent or polymerizable resinous material from its containerized state into the spike cavity; thereafter fully inserting a spike into the spike cavity.
 14. A method according to claim 13 wherein the bonding agent comprises an epoxy;
 15. A method according to claim 13 wherein the resinous material comprises foamable polyurethane;
 16. A method according to claim 13 wherein the fully inserting act is into the resinous material and occurs at a time selected from the group consisting of immediately following polymerization, after partial curing has occurred and after full curing has occurred.
 17. A method according to claim 13 wherein further comprising the act of impregnating a wall defining the spike cavity with the bonding agent or resinous material to strengthen the wall and cure any wall defects.
 18. A method according to claim 13 wherein the inserting act comprises keeping the resinous material and an activator separate while containerizing both.
 19. A method according to claim 13 wherein the inserting act comprises confining the resinous material and the activator in separate frangible compartments while containerized.
 20. An on-site method for addressing the problem of loosened railroad spikes in previously formed spike cavities in railroad ties comprising the acts of: removing railroad spikes from associated railroad spike cavities to expose the spike cavities; inserting capsulized foamable polyurethane and activator into the exposed spike cavities; displacing a railroad spike into each capsule contained within the spike cavities rupturing each capsule causing the polyurethane and the activator to commingle to polymerize and foam the polyurethane in each spike cavity; whereby the polyurethane foam securely adheres the spikes in each spike cavity.
 21. In combination: a railroad tie; a spike cavity in the railroad tie; an encapsulated composition disposed in the spike cavity; whereby release of the composition within the spike cavity will firmly secure an inserted railroad spike in the spike cavity.
 22. A method of securing a railroad spike in a pre-used spike cavity in a railroad tie comprising the acts of: providing a railroad tie with an exposed pre-used spike cavity therein; placing an encapsulated composition in the pre-used spike cavity; causing release of the composition within the spike cavity; firmly securing an inserted railroad spike in the spike cavity with the released composition. 